M+W Process Automation

SIL Assessments and Verifications in the

Process Industry

Ein Unternehmen der M+W Group

A Company of the M+W Group

Bram Van Liefferinge

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SIL Assessments and verifications in the

process industry
Content
Bram Van Liefferinge
IEC 61511
M+W Process Automation

Company Presentation

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M+W Process Automation A Company of the M+W Group

M+W Process Automation

Bram Van Liefferinge
TV FSE 625/07
Project Engineer
Head Functional Safety Departement

Company Presentation

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M+W Process Automation A Company of the M+W Group

SIL Process Industry

IEC 61511
Functional Safety - Safety Instrumented Systems for the Process Industry
Who?
Why?
What about?
How?

Company Presentation

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M+W Process Automation A Company of the M+W Group

IEC 61508 >< IEC61511

IEC 61508
=> Manufacturers & Suppliers
IEC 61511
=> End Users & System Integrators

Company Presentation

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M+W Process Automation A Company of the M+W Group

Who?
Seveso II Directive:
control of major-accident hazards involving dangerous substances
High level Seveso company
Low level Seveso company
Kind of substance
Amount of substances
Seveso locaties in Belgium:
173 H
194 L

Company Presentation

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M+W Process Automation A Company of the M+W Group

Why?
Seveso Directive:
Take all necessary measures and show to inspecting authorities that all necessary
measures are fullfilled.
=> Which measures and why
High level of protection
=> Codes of good practise: IEC 61511
PAM:

Preventive Active Measures

Belgium: Seveso
MES 3-audit

Func. Safety: PAM

Company Presentation

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M+W Process Automation A Company of the M+W Group

What about?
Risk Reduction with:
Sensor

Company Presentation

SIS
Logic

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Actor

M+W Process Automation A Company of the M+W Group

How?
Lifecycle concept
How do I build an SIS?
How do I keep my SIL / Risk reduction?

Company Presentation

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M+W Process Automation A Company of the M+W Group

Hazard and Risk Analysis

Seveso: To take all necessary measures and to show inspecting authorities
that all necessary measures are fullfilled.
Identify Hazards
Define Risks

Without safeguards!
Risk = Probability x Severity

Define necessary risk reduction

10

Company Presentation

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M+W Process Automation A Company of the M+W Group

Allocation of Safety Functions

to Protection Layers
Risk unacceptable?
Identify existing safeguards
Define additional safeguards
Intrinsic Safe Design
Mechanical Protection Layer
Instrumental Protection Layer (SIL)
Passive protection layers (dyke)
Human intervention

S
S
A
SIL

!
D
E
ESS

LOPA, matrix, risk graph

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Company Presentation

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M+W Process Automation A Company of the M+W Group

Safety Integrity Level

Measure for the reliability of the SIS (PFD)
SIL3 much harder then SIL1
RRF = 1 / PFD

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Company Presentation

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M+W Process Automation A Company of the M+W Group

IEC 61511 Lifecycle

13

Company Presentation

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M+W Process Automation A Company of the M+W Group

Safety Requirements Specification

Why is this so important?

=> Emphasis government: PAM

14

Company Presentation

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M+W Process Automation A Company of the M+W Group

Safety Requirements Specification

SIF Safety Requirement Specification

Functional requirements

Integrity requirements

General concept

PFD-calculations to determine

SIF specification

Test Interval

SIL

=> Safety

STL (Spurious Trip Level)

=> Availability

PFD-calculation
Design & Engineering

15

Before basic/detail/software engineering

Basis for documentation

Basis for validation

Company Presentation

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M+W Process Automation A Company of the M+W Group

Safety Requirements Specification

IEC 61511 & PAM

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Trip setting

Safe operating limit + argumentation

Response time requirements

Diagnostics

Reset functions

Additional risks because of trip?

Fail actions

Demands rates

Test interval and repair times

When is the function active? (start up, normal operation,...)

...

Company Presentation

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M+W Process Automation A Company of the M+W Group

Engineering

Allocation of safety functions

=> Risk Reduction & PFD

Safety Requirements Specification

=> Functionality

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Company Presentation

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M+W Process Automation A Company of the M+W Group

SIL Verification

Architectural Constraints

HFT

SFF

PFDavg

Failure rate (Lambda )

Architecture

Diagnostic Coverage

Common cause (Beta )

Test Interval (TI)

Mean time to repair (MTTR)

Demand mode
Architectural Constraints
=> SIL
PFD (SIF)

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Company Presentation

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M+W Process Automation A Company of the M+W Group

Failure Rates

Sources:

19

Vendor data (certified or not)

Oreda

Exida

...

Company Presentation

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M+W Process Automation A Company of the M+W Group

Architectural Constraints

Hardware Fault Tolerance (HFT)

How many hardware failures may occure without loss of the safety function?

1oo1
1oo2
1oo3
2oo3

SFF from SIL certificate vendor

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Company Presentation

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M+W Process Automation A Company of the M+W Group

Architectural Constraints
IEC 61508

IC/Software => Type B!

SIL2 application simple pressure measurement

=> 1oo1

SIL2 application temperature measurement smart

=> 1oo2

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Company Presentation

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M+W Process Automation A Company of the M+W Group

Architectural Constraints
IEC 61511

Dominant failure = safe failure

SIL2 application simple pressure measurement

=> 1oo2

SIL2 application temperature measurement smart

=> 1oo2

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Company Presentation

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M+W Process Automation A Company of the M+W Group

Architectural Constraints
IEC 61511 Loophole
HFT may be reduced by one if:
Hardware of the device selected on prior use basis
Only process related parameters may be adjusted
Parameters protected
SILSIF < SIL 4

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Company Presentation

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M+W Process Automation A Company of the M+W Group

PFDavg: Architecture
1
PFD1oo1 DUTI
2
PFD1oo2

2DUTI2

1
DUTI
3
2

PFD 2oo2 DU TI
PFD 1oo3

PFD

24

2oo3

Company Presentation

3DU TI3
4

2
DU

1
DU TI
2

1
T I DU T I
2
2

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M+W Process Automation A Company of the M+W Group

PFDavg: Diagnostic Coverage

Sensors
External comparison => 90% du detected
Logic
PLC
Longer Test Interval!

DC > 99%
Relay Systems
DC = 0
Final Elements
On/Off valve: DC=0
Partial Stroke testing: 60%

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Company Presentation

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M+W Process Automation A Company of the M+W Group

PFDavg: Common cause

IEC 61511-1 3.2.6.1 common cause failure
failure, which is the result of one or more events, causing failures of two or more
separate channels in a multiple channel system, leading to system failure
determined by:

Separation of channels

Diversity

Procedures / Training / Test methods

Environment

...

can have a significant impact!

estimation:

Conservative (10%)

Tables IEC 61508

Exida

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Company Presentation

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M+W Process Automation A Company of the M+W Group

PFDavg: TI, MTTR and Demand Mode

Test Interval

Mean Time To Repair (MTTR)

Limited influence
Spare available!
Repair must be possible!

Demand Mode
Process => Normally Low Demand Mode

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Company Presentation

=> PFD

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1
PFD1oo1 DUTI
2

M+W Process Automation A Company of the M+W Group

SIL Verification

Architectural Constraints

PFD Calculations

=> PFD (SIF) => SIL Achieved!

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Company Presentation

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M+W Process Automation A Company of the M+W Group

IEC 61511 Lifecycle

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Company Presentation

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M+W Process Automation A Company of the M+W Group

Conclusion

SIL Assessments & Verifications are not easy!

No experience? Get help!

30

Company Presentation

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M+W Process Automation A Company of the M+W Group

Organization of the M+W Group

M+W Group GmbH

Dr. Hannes Rosenthaler

Juergen Wild (Speaker of the Board)

100%

Facility Solutions

Process Solutions

Product Solutions

3.306 Employees

825 Employees

224 Employees

M+W Asia Limited,

Singapore

M+W Process Automation

GmbH, Ludwigshafen
M+W Process Industries
GmbH, Stuttgart
Chemical
Pharmaceutical
Biotech
Automotive
Food and Beverage
Water / Waste Water
Oil and Gas
Energy

M+W Products GmbH,

Stuttgart

Juergen Wild

Herbert Blaschitz

Electronics
Flat Panel Displays
Photovoltaic
Energy /
Renewable Energy

Juergen Wild

Clean Room Systems

Clean Room Products

Others
Fac.Eng.GmbH
Real Estate
IT / Caatoosee (51%)

NumberAnzahl
of employees
der Mitarbeiter
of the M+W
der M+W
Group:
Group:
4.5244.524
Annual
- Gesamtumsatz
sales revenue
ca.
approx.
1,73 Mrd.
1,73billion

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Company Presentation

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M+W Process Automation A Company of the M+W Group

Organization Process Solutions

Business Unit Process Solutions

Head: Juegen Wild

M+W Process Automation GmbH

Headquarters: Ludwigshafen

M+W Process Industries GmbH

Headquarters: Stuttgart

470 Employees, Sales 2008: 63 M

386 Employees, Sales 2008: 95 M

Automation

Process Plant Engineering

Chemicals
Pharmaceuticals
Food and Beverage
Biotech
Water / Waste Water
Oil and Gas
Energy
Automotive

Biotech
Pharmaceuticals
Chemicals
Food and Beverage
Cosmetics

Management:
Andreas Bieber, Franz Greisberger &
Henning Hammerstaedt

Regional Office B + NL
50 Employees
Locations B: Melsele, Wavre,
Locations NL: Breda

Management:
Dr. Tobias Luecke,
Hermann Schwarzkopf

Management:
Stephan Hoste

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Company Presentation

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M+W Process Automation A Company of the M+W Group

M+W Process Automation

Consulting
Start-Up

Design

Basic
Engineering

Training
Detail
Engineering

Service

Specification
Validation

Control Cabinet
Mounting
Installation

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Company Presentation

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Project Management
Supply
Management

PLC and DCS

Robot
Programming

Manufacturing
&
Business
Integration

M+W Process Automation A Company of the M+W Group

Thank you for your attention!

If you have any questions...

Ein Unternehmen der M+W Group

A Company of the M+W Group

Bram Van Liefferinge

Eric Vohy
Version: May 2010

Doc.-Vers.: 16